Installation

1NZ-FXE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL NO. 1 FUEL TANK CUSHION
(a) Install 9 new cushions to the fuel tank.
2. INSTALL NO. 1 FUEL TUBE CLAMP

(a) Install the 2 clamps to the fuel tank.

3. INSTALL FUEL TANK RETAINER LH
(a) Install a new gasket to the fuel tank.
(b) While being careful that the gasket does not drop in the fuel tank, insert the fuel tank retainer LH into the fuel tank so the protrusion of the fuel tank retainer LH is in the middle of the 2 convex pats of the fuel tank.

4. INSTALL FUEL TANK PRESSURE SENSOR
(a) Push the fuel tank pressure sensor to the plug of the fuel tank retainer LH, and then install the tube joint clip.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank pressure sensor and fuel tank retainer LH before this procedure.
- Check that the fuel tank pressure sensor is securely inserted to the end.
- Check that the tube joint clip is on the collar of the fuel tank pressure sensor.
- After installing the tube joint clip, check that the fuel tank pressure sensor cannot be pulled out.

5. INSTALL CANISTER

(a) Install the nut to the fuel tank.

(b) Install the canister with the bolt and 2 nuts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
(c) Connect the No. 1 canister outlet hose to the fuel tank.
(d) Connect the canister hose to the fuel tank retainer.

6. INSTALL FUEL TANK WIRE
(a) Install the 3 wire harness clamps as shown in the illustration D.
(b) Connect the vapor pressure sensor connector as shown in the illustration C.
(c) Connect the VSV connector as shown in the illustration B.
(d) Install the clamp as shown in the illustration A.

7. INSTALL FUEL TANK VENT HOSE
(a) Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the trap canister with pump module.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector.

8. INSTALL TRAP CANISTER WITH PUMP MODULE

(a) Install a new gasket to the fuel tank.
(b) Insert the trap canister with pump module into the fuel tank.
NOTE: Be careful that the gasket does not drop in the fuel tank.

(d) Install the trap canister with pump module and connect the ground terminal of the fuel tank wire with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
(e) Install the fuel tank vent hose to the 2 fuel tube clamps.
(f) Install the clamp to the fuel tank vent hose and canister hose.
(g) Connect the VSV connector.
9. INSTALL FUEL TANK TO CANISTER TUBE

(a) Install the fuel tank to canister tube to the canister's hose.
(b) Connect the fuel tank to canister tube to the 2 No. 1 fuel tube clamps.

10. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY
(a) Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to install the fuel suction tube to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this procedure.
- After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector.

(b) Connect the fuel suction tube to the 2 No. 1 fuel tube clamps.
11. INSTALL NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Align the main tube connector with the pipe, and then push in the main tube connector until the retainer makes a "click" sound to install the No. 2 fuel tank main tube to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector.
- After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the main tube connector.

(b) Install the checker to the pipe.
(c) Connect the No. 2 fuel tank main tube to the clamp.

(d) Connect the connector clamp to the rear fuel tank bracket.
(e) Install the rear fuel tank bracket with the 3 nuts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
12. INSTALL FUEL TANK ASSEMBLY
(a) Set the fuel tank to a transmission jack.
(b) Operate the transmission jack, and then install the fuel tank to the vehicle.
(c) Operate the transmission jack, and then connect the fuel tank inlet pipe.

(d) Install the No. 1 fuel tank band RH and LH with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
(e) Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.

(f) Connect the No. 1 canister tube.
(1) Align the No. 1 canister tube connector with the pipe, and then push in the No. 1 canister tube connector until the retainer makes a "click" sound to connect the No. 1 canister tube to the fuel tank to filler pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the No. 1 canister tube connector and pipe before this procedure.
- After connecting the No. 1 canister tube, check that the No. 1 canister tube is securely connected by pulling the No. 1 canister tube connector.

(g) Connect the fuel suction tube.
(1) Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to connect the fuel suction tube to the fuel tank to filler pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the suction tube connector and pipe before this procedure.
- After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector.

(h) Connect the fuel tank vent hose.
(1) Align the fuel tank vent hose connector with the pipe, and then push in the fuel tank vent hose connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the canister filter.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the vent hose connector.

(i) Connect the No. 2 fuel tank main tube.
(1) Align the fuel tube connector with the pipe, and then push in the fuel tube connector until the retainer makes a "click" sound to connect the No. 2 fuel tank main tube to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this procedure.
- After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the quick connector.

(j) Install the checker to the pipe.

(k) Connect the fuel tank to canister tube.
(1) Align the fuel tank to canister tube connector with the pipe, and then push in the fuel tank to canister tube connector until the retainer makes a "click" sound to connect the fuel tank to canister tube to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank to canister tube connector and pipe before this procedure.
- After connecting the fuel tank to canister tube, check that the fuel tank to canister tube is securely connected by pulling the quick connector.

13. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. INSPECT FOR FUEL LEAK Testing and Inspection
16. INSPECT FOR EXHAUST GAS LEAK
17. INSTALL FRONT FLOOR PANEL BRACE Installation
18. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER Installation

19. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Attach new butyl tape to the rear floor service hole cover.
(b) Connect the wire to wire connector.
(c) Connect the fuel pump connector.
(d) Install the rear floor service hole cover while adjusting it to the 3 convex parts of the floor panel.
NOTE: Be careful that the rear floor service hole cover does not overlap the convex parts of the floor panel when installing.

20. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
21. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.